Carbon Fiber Electrode Casting With Lead Ribbon Attachment
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Solution Overview
Problem
There is a need for a cost-effective method to mass produce battery electrodes made of carbon fiber material attached to a lead conductor, as existing methods are inefficient and expensive.
Innovation Solution
A machine and process involving unwinding a longitudinally elongate strip of electrically conductive carbon fiber material, casting a continuous flow of liquid lead or lead alloy onto the strip to form a solidified ribbon, and then severing the strip into individual electrodes using a rotatable drum with spikes to retain the carbon fiber material and control the ribbon's attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional methods are used to produce carbon fiber electrodes with lead conductors, then production cost and efficiency are poor, but the patent introduces a continuous casting process using a rotatable drum with spikes to retain carbon fiber material and cast liquid lead onto it, enabling cost-effective mass production while maintaining electrode integrity and conductivity
Solution Approach 1:
The patent implements continuous production by unwinding a longitudinally elongate strip of carbon fiber material continuously and casting liquid lead onto it in a continuous manner along its length, eliminating batch processing interruptions and enabling sustained high-volume output
Solution Approach 2:
The rotatable drum with spikes provides dynamic retention of the carbon fiber strip during the casting process, allowing the strip to be fed continuously while maintaining proper positioning and tension through rotational motion rather than static clamping
2Productivity
If a continuous flow of liquid lead is cast onto the carbon fiber strip, then manufacturing speed increases, but control over ribbon solidification and attachment precision becomes challenging
Solution Approach 1:
The rotatable drum with spikes performs preliminary action by retaining and positioning the carbon fiber strip before the liquid lead is cast onto it, ensuring proper alignment and preparation of the substrate for precise ribbon formation during the high-speed casting process
Solution Approach 2:
The patent utilizes the phase transition of lead from liquid to solid state as it cools after being cast onto the carbon fiber strip, allowing the liquid lead to flow easily during casting then solidify into a precise ribbon shape that maintains its form and attachment integrity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the efficient and cost-effective production of composite battery electrodes with a carbon fiber material electrically connected to a lead conductor, facilitating mass production while maintaining the integrity and conductivity of the carbon fiber material.
Implementation Method 1
supplying liquid lead or lead alloy to a cavity of the rotatable drum via a shoe residing in complementary mating confrontation with a portion of a periphery of the rotatable drum. The liquid lead or lead alloy is supplied at a longitudinally elongate portion of the strip of carbon fiber material and establishes a solidified electrically conductive lead or lead alloy ribbon at the longitudinally elongate portion of the strip of carbon fiber material
Data Source
AI summary
A machine and process for making a composite battery electrode with a conductive lead cast ribbon extending along and attached to a portion of a carbon fiber material. A lead ribbon may be continuously cast along a longitudinally elongate strip of carbon fiber material. The ribbon may be cast along an edge or edges of a longitudinally elongate strip of carbon fiber material.